Protective garment with comfort collar

ABSTRACT

A protective garment including an outer shell having an outer collar, and an inner liner configured to be worn between the outer shell and a wearer. The inner liner includes an inner collar and a comfort collar configured to conformingly engage a neck of the wearer when the garment is worn.

This application claims priority to U.S. Provisional Application Ser. No. 61/452,425, filed on Mar. 14, 2011, the entire contents of which are incorporated by reference herein.

The present disclosure relates to protective garments, and more particularly, to protective garments for hazardous duty use.

BACKGROUND

Protective or hazardous duty garments are used in a variety of industries and settings to protect the wearer from hazardous conditions such as heat, smoke, cold, sharp objects, chemicals, liquids, fumes and the like. Such protective or hazardous duty garments are often used in adverse conditions, such as high heat, exposure to smoke or chemicals and the like. The protective garments are often constructed from sturdy and stiff materials to provide sufficient protection. However, the stiffness of the materials may cause chafing around the neck of the wearer.

SUMMARY

In one embodiment, the invention is a protective garment including an outer shell having an outer collar, and an inner liner configured to be worn between the outer shell and a wearer. The inner liner includes an inner collar and a comfort collar configured to conformingly engage a neck of the wearer when the garment is worn.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a protective garment, incorporating a cutaway section illustrating differing layers of the garment;

FIG. 2 is a front view of a liner of the protective garment of FIG. 1, removed from the outer shell;

FIG. 3 is a back view of the liner of FIG. 2;

FIG. 4 is a detail view of area indicated in FIG. 2;

FIG. 5 is a front view of the liner of FIG. 2, turned inside out;

FIG. 6 is a back view of the liner of FIG. 5;

FIG. 7 is a detail view of the area indicated in FIG. 5; and

FIG. 8 is a detail cross section view taken along line 8-8 of FIG. 4.

DETAILED DESCRIPTION

The following detailed description will illustrate the general principles of the invention, examples of which are additionally illustrated in the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.

FIG. 1 illustrates a protective or hazardous duty garment in the form of a firefighter's coat or garment, generally designated 10. The coat 10 may include a body portion 12 with a left front panel 14, right front panel 16 and a back panel 18. The left and right front panels 14, 16, when joined/overlapped, meet at a slit 19. The left front panel 14 and right front panel 16 may be releasably attachable to each other, thus closing the slit 19, by a fastener 20, such as a zipper, snaps, clasps, clips, hook-and-loop fastening material (i.e., VELCRO®), combinations of the forgoing or the like.

The body portion 12 may define a torso cavity 22 that is shaped to receive a wearer's torso therein. The coat 10 may include a pair of sleeves 24 coupled to and extending generally outwardly from the body portion 12 and may be shaped to receive a wearer's arms therein and cover at least about 90% of the arms of an average sized adult wearer.

The coat 10 may include various layers through its thickness to provide resistance to heat, moisture and abrasion so that the coat 10 can be used as a protective, hazardous duty or firefighter garment. For example, the coat 10 may include an outer shell 26, a moisture barrier 28 located inside of and adjacent to the outer shell 26, a thermal liner or barrier 30 located inside of and adjacent to the moisture barrier 28, and an inner liner or face cloth 32 located inside of and adjacent to the thermal barrier 30.

The outer shell 26 may be made of or include a variety of materials, including material that is resistant to flame, heat and abrasion, such as a compact weave of aramid fibers and/or polybenzamidazole fibers. Commercially available aramid materials include NOMEX and KEVLAR fibers (both trademarks of E.I. DuPont de Nemours & Co., Inc. of Wilmington, Del.), and commercially available polybenzamidazole fibers include PBI fibers (a trademark of PBI Performance Products, Inc. of Charlotte, N.C.). Thus, the outer shell 26 may be an aramid material, a blend of aramid materials, a polybenzamidazole material, a blend of aramid and polybenzamidazole materials, or other appropriate materials. If desired, the outer shell 26 may be coated with a polymer, such as a durable, water repellent finish (i.e. a perfluorohydrocarbon finish, such as TEFLON® finish sold by E. I. DuPont de Nemours and Company of Wilmington, Del.). The materials of the outer shell 26 may have a weight of, for example, between about 6-10 oz./yd².

The coat 10/outer shell 26 may include an outer collar 34 made of the same materials as described above for the outer shell 26, which can be relatively stiff and coarse. The collar 34 is positioned at the top of the garment 10 and may extend at least about 270 degrees about the garment/neck opening, up to 360 degrees or more. FIG. 1 illustrates the outer collar 34 turned down, although the outer collar 34 can be turned upon and extend generally vertically to cover/protect at least part of the neck of the wearer.

The moisture barrier 28 and thermal barrier 30 may be generally coextensive with the outer shell 26, or spaced slightly inwardly from the outer edges of the outer shell 26 (i.e., spaced slightly inwardly from the outer ends of the sleeves 24 and/or lower edge of the coat 10) to provide moisture and thermal protection throughout the coat 10. The moisture barrier 28 may include a semi-permeable membrane layer 28 a and a substrate 28 b. The membrane layer 28 a may be generally moisture vapor permeable but generally impermeable to liquid moisture.

The membrane layer 28 a may be made of or include expanded polytetrafluoroethylene (“PTFE”) such as GORE-TEX or CROSSTECH materials (both of which are trademarks of W.L. Gore & Associates, Inc. of Newark, Del.), polyurethane-based materials, neoprene-based materials, cross-linked polymers, polyamid, or other materials. The membrane layer 28 a may have microscopic openings that permit moisture vapor (such as water vapor) to pass therethrough, but block liquids (such as water) from passing therethrough. The membrane layer 28 a may be made of a microporous material that is either hydrophilic, hydrophobic, or somewhere in between. The membrane layer 28 a also may be monolithic and may allow moisture vapor transmission therethrough by molecular diffusion. The membrane layer 28 a may also be a combination of microporous and monolithic materials (known as a bicomponent moisture barrier), in which the microporous or monolithic materials are layered or intertwined.

The membrane layer 28 a may be bonded or adhered to the substrate 28 b of a flame and heat resistant material to provide structure and protection to the membrane layer 28 a. The substrate 28 b may be or include aramid fibers similar to the aramid fibers of the outer shell 26, but may be thinner and lighter in weight. The substrate 28 b may be woven, non-woven, spunlace or other materials. In the illustrated embodiment, the membrane layer 28 a is located between the outer shell 26 and the substrate 28 b. However, the orientation of the moisture barrier 28 may be reversed such that the substrate 28 b is located between the outer shell 26 and the membrane layer 28 a.

The thermal barrier 30 may be made of any suitable material that provides sufficient thermal insulation. In one embodiment, the thermal barrier 30 may include a relatively thick (i.e. between about 1/16″- 3/16″) batting, felt or needled non-woven material 30 a which can include aramid fiber batting (such as NOMEX batting), aramid needlepunch material, an aramid non-woven material, an aramid blend needlepunch material, an aramid blend batting material, an aramid blend non-woven material, or foam (either open cell or closed cell) materials. The batting 30 a may trap air and possess sufficient loft to provide thermal resistance to the coat 10.

The batting 30 a can be quilted to a thermal barrier face cloth 30 b which can be a weave of a lightweight aramid material. Thus, either the batting 30 a alone, or the batting 30 a in combination with the thermal barrier face cloth 30 b, may be considered to constitute the thermal barrier 30. In one embodiment, the thermal barrier 30 may have a thermal protection performance (“TPP”) of at least about twenty, or of at least about thirty-five, although the TPP performance can vary as desired. If desired, the thermal barrier 30 may be treated with a water-resistant or water-repellent finish. In the illustrated embodiment, the batting 30 a is located between the outer shell 26 and the thermal barrier face cloth 30 b. However, the orientation of the thermal barrier 30 may be reversed such that the thermal barrier face cloth 30 b is located between the outer shell 26 and the batting 30 a.

Although the moisture barrier 28 is shown as being located between the outer shell 26 and the thermal barrier 30, the positions of the moisture barrier 28 and thermal barrier 30 may be reversed such that the thermal barrier 30 is located between the outer shell 26 and the moisture barrier 28.

The face cloth 32 may be the innermost layer of the coat 10, located inside the thermal barrier 30. The face cloth 32 can provide a comfortable surface for the wearer and protect the thermal barrier 30 and/or moisture barrier 28 from abrasion and wear. In some cases, the face cloth 32 can be considered part of the thermal barrier 30.

Each layer of the coat 10, and the coat 10 as a whole, may meet the National Fire Protection Association 1971 standards (“NFPA Standards”) for protective firefighting garments (“Protective Clothing for Structural Firefighting”), which standards, as of the filing date of this application, are entirely incorporated by reference herein. The NFPA standards specify various minimum requirements for heat and flame resistance and tear strength. For example, in order to meet the NFPA standards, the outer shell 26, moisture barrier 28 and thermal barrier 30 must be able to resist igniting, burning, melting, dripping and/or separation at a temperature of 500° F. for at least five minutes. Furthermore, in order to meet the NFPA standards, all combined layers of the coat 10 must provide a thermal protective performance (“TPP”) rating of at least thirty-five.

The coat 10 may include an inner liner 100 (shown in FIGS. 2-4) including the moisture barrier 28 and thermal barrier 30 (and face cloth 32, if utilized) joined together to form the inner liner 100. The moisture barrier 28, thermal barrier 30 and face cloth 32 can be permanently coupled together, such as by stitching or the like, to form the integral inner liner 100. The inner liner 100 may be separable and removable from the outer shell 26 of the coat 10 so that the inner liner 100 can be cleaned separately, replaced when worn, or replaced by an inner liner having different thermal properties. The inner liner 100 can be releasably or removably coupled to the outer shell 26 by a variety of systems/devices, such as hooks, clasps, zippers, slide fasteners, snaps, clips, hook-and-loop fastening material (i.e., VELCRO®), and other well-known fasteners. Such a system is described generally in U.S. Pat. No. 6,687,913 and U.S. Patent Publication No. 2008/0209611; the contents of both of these publications are incorporated herein in their entireties. However, the inner liner 100 may not necessarily be removable/separable from the outer shell 26, and instead the inner liner 100 may be permanently coupled to the outer shell 26, or coupled in a non-manually-removable manner, such as by stitching, rivets, etc. In the illustrated embodiment the moisture barrier 28 is positioned outside the thermal barrier 30/face cloth 32 such that the moisture barrier 28 forms the outer-most surface of the inner liner 100.

FIGS. 2-4 show the inner liner 100 removed from the garment of FIG. 1. The moisture barrier 28 faces outward (away from the wearer) and covers the thermal barrier 30/inner liner 32. In the illustrated embodiment, the inner liner 100 includes a body portion 104 having a front slit 105, which is generally aligned with slit 19 of the shell 26 to facilitate donning and doffing the liner 100.

The inner liner 100 also includes an inner collar or collar portion 106 positioned at the top of the inner liner 100/slit 105, which may extend at least about 270 degrees about the liner 100/neck opening, up to 360 degrees or more. The inner collar 106 may be attached to the body portion 104 along a seam 108 that extends the entire circumferential length of the collar 106. The collar 106 may be made of the same combination of materials as the remainder of the inner liner 100, namely the moisture barrier layer 28, thermal barrier layer 30 and/or face cloth 32. In the illustrated embodiment, the collar 106 lacks the outer shell material, as this can be provided by the collar 34 which can, in some cases, be turned up and positioned adjacent to the collar 106, substantially or entirely covering the collar 106 and providing protective qualities thereto.

As shown in FIGS. 2 and 4 the face cloth 32 faces inwardly facing the neck of the wearer. The collar 106 can be, as a whole, relatively stiff such that, for example, the collar 106 (which can have a height of at least about one inch (2.54 cm) or at least about 2 inches (5.08 cm) extends generally vertically and retains its shape and positioning. The relative stiffness of the collar 106 may cause the collar 106 to not conform closely to the neck of a wearer, such that gaps are formed between the collar 106 and the neck of a wearer. Moreover, in some cases the face cloth 32 material is relatively rough against the relatively sensitive, exposed skin of the neck of a wearer.

Thus, in one embodiment the collar 106/coat 10 includes a comfort collar 110 positioned inside the collar 106. The comfort collar 110 is shown as extending the same circumferential distance as the collar 106, on an inner surface thereof, but can extend more or less of the circumferential distance of the collar 106. The comfort collar 110 thus can extend at least about 270 degrees about the liner 100/neck opening, up to 360 degrees or more. The comfort collar 110 can be made from a separate, discrete piece of material relative to the collar 106 and that is joined to the collar 106 and may, for example, lack a moisture barrier and/or thermal barrier. In one case the comfort collar 110 is joined to the body portion 104 of the inner liner 100 along substantially its entire length by the same seam 108 that joins the collar 106 to the body portion 104. However, the comfort collar 110 can also, or instead, be joined directly to the collar 106, or joined to the body portion 104 by a separate seam.

In the illustrated embodiment, the comfort collar 110 extends radially inwardly from the radially inner surface of the collar 106, and may be shaped and positioned to conformingly engage the neck of a wearer in a substantially gapless manner. In particular, in one case the comfort collar 110 has a length extending circumferentially thereabout, and the comfort collar 110 is configured to engage the neck of a wearer along substantially the entire length. Such engagement with the neck helps to seal out external moisture and prevent embers, liquids, and other debris from falling into the garment 10 via the neck.

FIGS. 5-7 illustrate the inner liner 100 of FIGS. 2-4 turned inside out. This orientation shows the comfort collar 110 extending along substantially the entire length of the collar 106. As shown in FIGS. 5 and 7, the ends 112, 114 of the comfort collar 110 taper generally downwards towards the seam 108 (reducing the height/thickness of the comfort collar 110). However, the comfort collar 110 may lack the tapered ends 112, 114, or may taper along the entire length of the comfort collar 110, depending on the shape desired. As shown in FIG. 7, the comfort collar 110 may have a height (or width 116) that is less than the height (or width) 118 of the collar 106. In addition, the upper edge of the comfort collar 110 is spaced away from (e.g. below) the upper edge of the collar 106. This configuration enables the collar 106 to protect the comfort collar 110 from thermal and moisture exposure and abrasions. However, if desired the height 116 of the comfort collar 110 may be equal to, or even greater than, the height 118 of the collar 106.

FIG. 8 is a sectional view of the collar 106 and comfort collar 110 shown in FIGS. 2-7. The comfort collar 110 and collar portion 106 may be joined at the seam 108, and in one case the collars 106, 110 are not be joined physically at any points higher than the seam 108. This feature enables the comfort collar 110 extend radially inwardly to close around the wearer's neck while the collar portion 106 may remain straight and away from the wearer's neck. In one case, then, the comfort collar 110, or at least an upper end thereof, may have a smaller diameter than that of the collar 106, or than lower portions of the comfort collar 110, and the comfort collar 110 may generally have a truncated-cone shape. In this manner the comfort collar 110 extends radially inwardly from the collar portion 106 such that the comfort collar 110 and collar portion 106 define an annular gap 109 therebetween that is open at its top end.

As can be seen in FIG. 8, the moisture barrier portion 28 of the inner collar 106 lies flush against, and is directly stitched to, the moisture barrier portion 28 of the body portion 104 of the garment 10. This arrangement helps to provide continuous moisture barrier protection to the garment 10.

The comfort collar 110 may be positioned on the inner/thermal barrier 30 side of the liner 100 of the coat 10. However, the comfort collar 110 can be positioned in various other manners without departing from the scope of the invention. For example, in a so-called reverse orientation, the moisture barrier 28 may form the inner-most layer of the inner liner 100, and in this case the comfort collar 110 may be secured to the moisture barrier 28, and the stitching line 108 sealed with a moisture resistant tape. Alternately, the comfort collar 110 may be attached directly to the collar 34 of the outer shell 26, or to one of the liner layers 28, 30 of the coat 10 if the coat does not include a separate liner 100.

The comfort collar 110 can be made of a variety of materials, including a knitted, woven or fleeced material, or a soft, non-woven material, and may be softer, less abrasive, less stiff and/or more comfortable against the skin of a wearer than the materials of the outer shell 26, moisture barrier 28, thermal barrier 30 and/or face cloth 32. This material of the comfort collar 110 may be a knit fabric, such as a material knitted from an aramid material such as NOMEX or KEVLAR, a blend of such aramid materials, a PBI material, or a blend of aramid and PBI materials. The comfort collar 110 can be treated with a durable, water-repellant finish to substantially prevent the absorption or penetration of liquid moisture therethrough. The comfort collar 110 can be made of a material the same as or similar to that used for the wristlets described in U.S. Pat. No. 6,038,700, hereby incorporated herein in its entirety.

The comfort collar 110 may include elastic properties such that, for example in one case, the comfort collar 110 can stretch at least about 10% in its plane when stretching forces are applied and return to its pre-stretched shape when such stretching forces are removed. Such elastic properties may ensure that the comfort collar 110 stretches and closes about the neck of the wearer when the liner 100 is worn. The elastic properties may be accomplished in a variety of ways, including but not limited to incorporating an elastic band within the comfort collar 110, incorporating elastic fibers into the fabric/material of the comfort collar 110, or pleating the fabric. The comfort collar 110 may be undersized relative to the expected neck size so that the comfort collar stretches when worn to closely conform to the neck of a wearer. For example, in one case the radially innermost portion of the comfort collar 110 may have a circumference of less than about 15 inches (less than about 38.1 cm), or less than about 13 inches (less than about 33.02 cm).

The comfort collar 110 also has been described and shown as being joined to inner liner 100 (or other portion of the coat 10) at the seam 108 (or a corresponding seam in another portion of the coat 10) between the body portion 104 and collar 106 and extending upwardly therefrom. However, the comfort collar 110 may be attached to the body portion 104/collar 106 at other positions and achieve similar results. For example, the comfort collar 110 may be attached to the body portion 104 at a position below the seam 108 and extend upwards to cover the seam 108 to provide further comfort to the wearer. Alternately, the comfort collar 110 may be attached to the collar 106 above the seam 108 and extend downwards for all or part of its width 116, potentially covering the seam 108.

Further, while the comfort collar 110 has been generally described as attached at its lower edge, the comfort collar 110 may feature additional attachment(s) at other point along its length, such as a seam running parallel, perpendicular, or angled relative to the seam 108, to ensure that the comfort collar 110 stays upright and does not bunch, fall, or become uncomfortable for the wearer. The comfort collar 110 can be attached to the liner 100 in other manners, including but not limited to attaching the comfort collar 110 at the top edge or along a seam in the middle of the comfort collar 110. In one case, the various collars 34, 106, 110 are configured in an overlapping manner such that a radial line extends through the outer collar 34 (i.e. when the outer collar 34 is folded up from its configuration shown in FIG. 1), the inner collar 106, and the comfort collar 110 to provide a three-ply collar arrangement. In other cases, when the outer collar 34 is folded down, a two-ply collar may be provided (although the inner collar 106 itself can be made of various plies).

The comfort collar 110 is illustrated as being attached to the liner 100 by the stitched seam 108. However, the comfort collar 110 may be attached to the liner 100 (or shell 26, or other part of the coat 10) by means other than by stitching. Such attachment may include, but is not limited to, adhesives, rivets or the like, or releasable fastening devices such as zippers, slide fasteners, snaps, clasps, clips, hook-and-loop fastening material (i.e., VELCRO®), and other well-known fasteners.

The comfort collar 110 also may have protective properties to increase the overall protection offered by the hazardous duty garment 10. In one case, as noted above, the comfort collar 110 is treated with a water-resistant, water-proof, or water-repellant finish. Such a feature can increase the comfort and safety of the overall garment 10 by preventing rain, snow, water from firefighting hoses, or other moisture from entering or wicking through the neck of the hazardous duty garment 10. The comfort collar 10 can be constructed from a flame or thermal resistant material or treated with an additive to increase flame or thermal resistance, such that the comfort collar 110 complies with NFPA or other relevant regulations. Other variations of protective properties, either alone or in combination, may be added to the comfort collar 110, based on the intended use of the hazardous duty garment.

Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention which is defined in the appended claims. 

1. A protective garment comprising: an outer shell having an outer collar; and an inner liner configured to be worn between the outer shell and a wearer, the inner liner including an inner collar and a comfort collar configured to conformingly engage a neck of the wearer when the garment is worn.
 2. The protective garment of claim 1 wherein the inner liner is releasably attachable to the outer shell.
 3. The protective garment of claim 2 wherein said inner liner includes a moisture barrier and a thermal barrier that are permanently coupled together, and wherein the inner liner is entirely removably from the outer shell.
 4. The protective garment system of claim 3 wherein said thermal barrier has a TPP of at least about twenty, and wherein said moisture barrier is made of a material that is generally liquid impermeable and generally moisture vapor permeable.
 5. The protective garment of claim 1 wherein said comfort collar extends radially inwardly from said inner collar such that said comfort collar and said inner collar define an annular gap therebetween.
 6. The protective garment of claim 1 wherein a radially inner-most portion of said comfort collar has a circumference of less than about 15 inches.
 7. The protective garment of claim 1 wherein said comfort collar is generally elastic.
 8. The protective garment of claim 1 wherein said comfort collar is made of a material that is softer than said inner collar and said outer collar.
 9. The protective garment of claim 1 wherein said inner collar has an upper edge extending around a periphery thereof, and wherein said comfort collar is entirely vertically spaced below from said upper edge.
 10. The protective garment of claim 1 wherein said inner liner includes a body portion, and wherein said inner collar and said comfort collar are both coupled to said body portion by a common seam.
 11. The protective garment of claim 1 wherein said inner collar is joined to said inner liner by a seam, and wherein said comfort collar generally covers said seam such that said comfort collar is positioned between said seam and said wearer when said garment is worn.
 12. The protective garment of claim 1 wherein said comfort collar has a length extending circumferentially thereabout, and wherein said comfort collar is configured to engage said neck of said wearer along substantially the entire length.
 13. The protective garment of claim 1 wherein said comfort collar is made of a water repellent material or made of a material that is treated to be water repellent.
 14. The protective garment of claim 1 wherein said comfort collar is the inner-most layer of said garment in the neck area of said garment.
 15. The protective garment of claim 1 wherein said inner liner includes a moisture barrier and a thermal barrier, and wherein said inner collar includes a moisture barrier and a thermal barrier.
 16. The protective garment of claim 15 wherein said moisture barrier of said inner liner and said moisture barrier of said inner collar are in direct contact to provide continuous moisture barrier protection.
 17. The protective garment of claim 1 wherein said inner liner is configured to be positioned between said outer shell and said wearer when said garment is worn.
 18. The protective garment of claim 1 wherein the comfort collar is made of flame and heat resistant material.
 19. The protective garment of claim 1 wherein said outer collar, said inner collar, and said comfort collar are all made of separate and discrete pieces of material, and are configured such that a radial line extends through said outer collar, said inner collar, and said comfort collar to provide a three-ply collar arrangement.
 20. The protective garment system of claim 1 wherein the outer shell and outer collar are made of a material that resists igniting, burning, melting, dripping, or separation when exposed to temperatures of 500° F. for five minutes.
 21. The protective garment of claim 1 wherein the inner liner is permanently attached to the outer shell.
 22. A protective garment system comprising: an outer shell having a torso portion and an outer collar; and an inner liner positioned within the outer shell, said inner liner having a torso portion and an inner liner collar, the inner liner further including a comfort collar attached to the torso portion of the liner and being configured and positioned to conformingly engage a neck of a wearer of the garment system.
 23. A protective garment comprising: an outer shell made of an abrasion-resistant material that resists igniting, burning, melting, dripping, or separation when exposed to a temperature of 500° F. for five minutes; an inner liner configured to be worn between the outer shell and a wearer, the inner liner having a moisture barrier, a thermal barrier, the inner liner further including a body portion and an inner liner collar; and a comfort collar coupled to said inner liner, and wherein said inner liner collar and said comfort collar liner are both coupled to said inner liner body by a single, common seam. 